Mattress



0ct. 15, 1940.v T. N. PATTON 2,218,478,

MATTRESS Filed Feb. 5, 1940 (E. v/omas /l/PQH f fg A (di e tuftless structures.

Patented Oct. `15,` 1940 starrt oFFici;

\ MATTRESS Thomas Patton, Memphis, Tenn. Application February 5, 1940,Seria l No. 317,276

8 Claims.

, The present invention relates to improvements Vin mattresses of the type known as tuftless mattresses and "inner tufted structures of this type, and has `for its` main object to overcome certain objections to the aforesaid .types of `Inattresses resulting from` gradual compaction of the .ii-bre batts overlying the `spring assemblies of spring-filled mattresses and' o-ther types of said structures devoid of spring cores.

The said tuftless mattresses have attained great popularity because they present smooth surfaces when new, and are devoid of the hollows and exposedtufting buttons or other tufts which interfere greatly with proper clean-sing of thefcuter surfaces by brushing, etc. UBy reason of the gradual compaction of the fibre batts, as aforesaid, the cover fabrics, which are originally maintained taut by the superiicial portions of the bre batts, are gradually relieved of the resulting tension to such an extent that the said cover fabrics wrinkle and `present the equivalent of pleats which not only detract from the appearance of the mattress,`but arevery objectionable from the standpoint of discomfort and annoyance to occupants of beds equipped with such The foregoing objections are more pronounced, generally, in the inner-tufted mattresses than in the` type wholly devoid lof, tuftsfbecause of hollo-ws in the superficial parts *of the padding of thestructures, although the'inner-tufted Y(sometimes referred to as invisible tufts) mattresses are less liable to deformity than those wholly devoid of the tuft because the liability to separa-y tion of the outer padding layers is greatly decreased.

A further vobject ofthe present invention therefore, .to employ superficial batts so constructed asqto overcome' theliability to parting of the component libres thereof `,without resort .to the use ofinner tuftslor other means tending to producesuperlicial hollows in the outer batt portions and to so associatesaid batts with i 1 will be readily understood ,from the following specificati-on.

A suitable. embodiment of the invention is illustrated in the accompanying drawing, wherein:

Fig. l is a fragmentary sectional View illustrating the top portion of a mattress embodying the invention inprocess of construction. 5v`

Fig. 2 is a View similar to Fig. l showing'the y finished mattress.

In constructing the mattress of this invention, it is preferred to employ a conventional type of 1 spring assembly l, having iibre batts 2 disposed 10 over itstop and bottom faces and firmly lsecured tothe same. Y

In the instance illustrated the'spring assembly l is of the type illustrated anddescribed in 'UL Si. Patent to Suekoff blo-1,053,675, the termi- 1liV nal coils of the springs beingdisposed in square fiat pockets Sformed between two sheets l of fabric secured together by means of stitch chains 5 extending transversely of each other, but any other suitable type of spring assembly may be 2U used in place thereof.

It has been demonstrated that the thicker the entire padding disposed between the faces of the spring assembly I and the top and bottom fabric walls 6 of thel mattresscasing l, the less 25 will be th-eultimate degree of compaction of such padding due to loads thereon particularly if said padding is of a superior quality whichretains its"resiliency for along period` of time.

Preferably, the padding layers 2 consist of 30d sisal libre batts of conventional type which, due to the coarseness of the libres, present relatively rough surfaces.

.Al-so, preferably, batts` 8' of relatively long fibre cotton are ydisposed Jover the batts 2 and 35 lbetween the latterand sisal fibre batts 9, the

ofstitch chains l2 whichextend entirely through n said batts it, lbut so'loosely as not to form bis- 50 cuit'formations on the batt surfaces. The stitchchains l2 are sufficiently closely spaced and of such number as will serve to prevent the breaking up of the .batt I0 asbyparting thereof along lines that commonly extendlongitudnally of the 55" batt and result from occupants of the mattress rolling from side to side of the latter.

The batts I0 are of appreciably greater width and length than the casing 'I and have their marginal edge portions turned inwardly into embracing relation to the batts 8 and 9 and may extend, as shown, to project beyond the batts 2, if desired, and are compressed against the peripheries of the batts embraced thereby, by the peripheral wall or boxing strip of the casing lI. Stitch chains I3 may be employed to secure the depending marginal edge portions of the batt Ill to the cover fabric of the spring assembly as shown in Fig. 2.

The top and bottom'walls 6 of the casing 'I are cemented throughout their area to the fabric cover sheet II of the batt I0, by means of an adhesive substance that will remain permanently flexible and which will permeate the said sheet I I and the superflcially disposed fibres of the batt II) adjacent said cover sheet. This cementing operation is performed. before the batt IIB is disposed over the batt 9 in the manner shown in Fig. l and after being so placed the marginal edge portions of the batt I0 are turned to substantially the position shown in Fig. 2, and thereupon, the boxing strip of the casing is secured to the peripheral edges of the fabric walls 6 in the modern conventional manner to complete the mattress.

Obviously, the rough outer surfaces of the batts 9 cooperate with the walls 6 of the casing to hold the battsIIl in place, this being further accomplished by the cooperation of the marginal edge portions of the batts I 0 with the peripheral edges of the batts 9 or the latter and 'the batts s and 2.

Obviously, the batts 8 and 9 may be omitted and thicker batts 2 and IIl used, if desired, and especially so if the height of the spring assembly i I is greater than that partly shown in the drawing.

The adhesive may be first applied to the cover fabric sheet II, over the whole surface of same, to constitute a primary coating which will permeate the adjacent portion of the batt I0 and said coating may be allowed to dry before the cover sheet II is cemented to the Wall 6 of the casing, a coating of said adhesive being then applied to the latter and the same disposed over the sheet I I or vice versa.

Obviously, the superficial fibres of the batt I0 opposed to the sheet II serve to cooperate with said sheet to constitute the substantial equivalent of a layer of quilting interposed between the body of the batt I0 and the wall 6 which is held against movement relativevto the latter and prevents any wrinkling of Vthe latter even though the entire mass of padding becomes compacted in whole or in part. Due to the permanent fiexibility of the adhesive, the load supporting surfaces of the mattress shape themselves readily to the occupant without the slightest discomfort.

Obviously, the adhesive serves also to secure the stitch chains to the wall 6 and this serves to some extent, at least, to prevent any breaking apart of the batt IIJ.

-I claim as my invention:

1. In a mattress, a batt of fibrous material equipped with a cover. fabric disposed over one -face of said batt, series of relatively closely spaced stitch-chains securing said cover fabric to said batt and extending through the latter for preventing separation of the body portion of said batt, an outer cover fabric of said mattress being Acemented to the cover fabric of said batt through' out the area of the cover fabric of said mattress by means of a permanently elastic adhesive substance.

2. In a mattress, an outer batt of fibrous material underlying a cover fabric of a face portion of the mattress and including a cover fabric overlying a face of said batt and secured to the latter by a plurality of stitch-chains extending through the batt in relatively closely spaced relation to each other and traversing the same from edge to edge, said respective cover fabrics being cemented to each other over the entire area of said cover fabric of said mattress by means of a permanently flexible adhesive substance engaged with the portions of said stitch-chains directly opposed to the cover fabric of the mattress.

3. In a mattress, a batt of brous material of greater length and width than the said mattress disposed in surface contact with a fabric wall of said mattress over the entire area of said wall, series of relatively closely associated stitch-chains extending through said batt throughout substantially its entire area, said batt and wall of said mattress cemented by means of a permanently flexible adhesive substance engaging the stitch chain portions immediately opposed to said wall, a filler for the body of the mattress underlying the other face of said batt, the marginal edge portions of the latter disposed about the peripheral edge of said filler.

4. In a mattress, a batt of fibrous material of greater length and width than the said mattress disposed in surface contact with a fabric Wall of said mattress over the entire area of said wall, series of relatively closely associated stitch-chains extending through said batt throughout substantially its entire area, a cover fabric overlying the face of said batt opposed to said wall and secured to said batt by means of stitch-chains, said wall of said mattress and said cover fabric of said batt cemented together by means of a permanently flexible adhesive substance engaging the stitch chain portions immediately opposed to said wall, a filler for the body of the mattress underlying the other face of said batt, the marginal edge portions of the latter disposed about the peripheral edge of said ller.

5. In a mattress equipped with a spring assembly and batts of relatively coarse bre batts overlying the faces of said assembly, batts of relatively ne fibred material, such as cotton, disposed over said first-named batts, said last-named batts equipped with series of relatively closely associated stitch-chains extending through said batt throughout substantially its entire area and tions embracing the periphery of each of said first-named batts, cover fabrics extending over the entire outer faces of each of said secondnamed batts and secured to the latter by series of h relatively closely associated stitch-chains extending through each of said second-named batts throughout substantially the entire area thereof, said second-named batts having their fabric coverings opposed directly to the top and bottom Walls of the mattress casing and secured thereto over the entire area of said top and bottom Walls by means of a substantially permanently flexible adhesive substance.

7. A mattress comprising a resilient core portion, a conventional casing, preformed unitary self-restoring resilient pads interposed between the top and bottom walls of the casing and the said pore portion, and a lm of a permanently exible adhesive material connecting the said top and bottom walls of the casing with the opposed Surfaces of said pads.

8. A mattress comprising a .resilient core portion, a conventional casing, preformed unitary self-restoring resilient pads interposed between the top and bottom Walls of the casing and the said pore portion, and a lm of a permanently flexible adhesive material connecting the said top and bottom Walls of the casing with the opposed surfaces of said pads, thelatter including margina1 portions partly enveloping said core portion.

THOMAS N. PATTON. 

